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Reduce the excess air loss and compressor power consumption.

Aim:-
Reduce the excess air loss and compressor power consumption.

Introduction: -
There is pneumatic conveying system for Bed ash and Fly ash. Service Air is used for convey
these materials. In this system, orifice is used in conveying line. In this orifice there are
number of holes to supply the air in conveying line, which consumes high air. So to reduce
the excess air consumption, there was need to modify the orifice in conveying system.

Objective:-
Modification of orifice in conveying system to reduce the compressor power consumption
Which results in auxiliary power reduction.

Observation:-
For smooth operation of conveying system, there is need of sufficient amount of air. In our
conveying system old orifice was used, which consumes high air. So to maintain air pressure
compressor took high power. So to reduce the compressor power consumption, there is need
to modify the conveying system,

Recommendation:-
Modification of orifice in conveying system

Solution:-
For smooth operation of conveying system, there is need of sufficient amount of air. In our
conveying system old orifice was used. In this old orifice there are number of holes to supply
the air in conveying line, which consumes high air. So to maintain air pressure, compressor
took high power. So to reduce the excess air consumption, there was need to modify the orifice
in conveying system which reduces these excess air. To modify the orifice first we calculate
the hole diameter in new orifice by using the formula,

(∏/4)*D²*number holes in old orifice = (∏/4)*(D2)²*number holes in new orifice

Where, (D2) is the hole diameter in new orifice
After this we calculate the flow through conveying line with the help of anemometer.

1 Improving Your Business is Our Business- Thermax Ltd

P&E Team, JK Cement Works, Mangrol, Rajasthan
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Reduce the excess air loss and compressor power consumption.

Conclusion:-
Saving in Auxiliary power consumption @ 1000 KWH/day & Service air compressor running
hours are also reduced.

Benefits:-
Reduce Auxiliary power consumption by reducing compressor power consumption. Before
modification of orifice, service air compressor power consumption was 4500 KWH and after
modification of orifice, service air compressor power consumption is 3500 KWH. Now we
utilize only ONE compressor for service and instrument air.

Saving in Rupees = 1000* Rs.5/Unit

= Rs.5000/Day
= Rs. 18, 00,000/Annum.

BEFORE AFTER

2 Improving Your Business is Our Business- Thermax Ltd

P&E Team, JK Cement Works, Mangrol, Rajasthan